Slot designs in wide metal lines

ABSTRACT

A method and structure for slots in wide lines to reduce stress. An example embodiment method and structure for is an interconnect structure comprising: interconnect comprising a wide line. The wide line has a first slot. The first slot is spaced a first distance from a via plug so that the first slot relieves stress on the wide line and the via plug. The via plug can contact the wide line from above or below. Another example embodiment is a dual damascene interconnect structure comprising: an dual damascene shaped interconnect comprising a via plug, a first slot and a wide line. The wide line has the first slot. The first slot is spaced a first distance from the via plug so that the first slot relieves stress on the wide line and the via plug.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of co-pending U.S. patentapplication Ser. No. 10/923,123, filed on Aug. 21, 2004, the disclosureof which is hereby incorporated by reference in its entirety for allpurposes.

BACKGROUND OF INVENTION

1) Field of the Invention

This invention relates generally to design and fabrication of metallines and more particularly to fabrication of slots in metal lines forsemiconductor devices.

2) Description of the Prior Art

The downward scaling of feature sizes in very large scale integration(VLSI) fabrication has resulted in the transition of the interconnecttechnology from Aluminum (Al) to Copper (Cu) for faster deviceperformance. Owing to the differences between Al and Cu process, studieson the reliability performance such as electromigration (EM) between Aland Cu interconnects had since rose in importance. Less attention hasbeen focused on the study of stress-induced voiding in Cu interconnectsbecause of its favorable properties such as lower mobility and similarintrinsic stress level as compared to Al interconnects. However, thisassumption has been illustrated to be opportunistic because of copper'sstrong dependency on process and structure.

Relevant patent and technical literature are shown below.

U.S. Pat. No. 6,528,883—Dunham, et al.—shows Shapes-based migration ofaluminum designs to copper damascene. An interconnect structure for usein semiconductor devices which interconnects a plurality of dissimilarmetal wiring layers, which are connected vias, by incorporating shapedvoids in the metal layers.

U.S. Pat. No. 5,959,360 Fu—shows an interconnect structure employingequivalent resistance paths to improve electromigration resistance.

US 20030228714 A1—Smith et al. Dummy fill for integrated circuits—Thedescribed methods use process variation and electrical impact to directthe insertion of dummy fill into an integrated circuit.

U.S. Pat. No. 6,391,766—Wang, et al. shows a method of making a slot viafilled dual damascene structure with middle stop layer.

U.S. Pat. No. 6,489,684 Chen,et al. shows a reduction ofelectromigration in dual damascene connector. Local back-diffusionsources serve to increase back pressure on the metallic ions that makesup the wire, thereby reversing the trend towards electromigration. Thesesources are located close to the vias in question and may take the formof discrete local areas where the wiring is wider or they may beintroduced in the form of dummy vias.

U.S. Pat. No. 5,696,030—Cronin Integrated circuit contacts havingimproved electromigration characteristics and fabrication methodstherefor. Increased cross-sectional contact sections are employed, withconducting studs in contact therewith.

SUMMARY OF THE INVENTION

Embodiments of the present invention provides a structure and method offorming an interconnect structure comprising a wide line having a slot.The slot relieves stress induced voids and vacancies in theinterconnect.

An embodiment is an interconnect structure with slot(s) in wide lines toreduce stress. The interconnect structure preferably comprises: aninterconnect comprising a wide line; the wide line has a first slot; avia plug in contact with the wide line from above or below; the firstslot is spaced a first distance from a via plug so that the first slotrelieves stress and/or induced voiding on the wide line and the viaplug.

Another embodiment is a dual damascene interconnect Structurecomprising: an dual damascene shaped interconnect comprising a via plug,a first slot and a wide line; said wide line having said first slot;said first slot is spaced a first distance from said via plug so thatsaid first slot relieves stress on the wide line and the via plug.

Another embodiment is an interconnect structure comprising: a lowerinterconnect comprised of a wide line; said wide line having a firstslot; an upper interconnect comprised of a via plug; said via plugcontacting the top surface of said wide line; said first slot is spaceda first distance from said via plug so that said first slot relievesstress on the wide line and the via plug.

The embodiments of the invention further comprise the method to make theslots are defined further in the specification and claims.

The above and below advantages and features are of representativeembodiments only, and are not exhaustive and/or exclusive. They arepresented only to assist in understanding the invention. It should beunderstood that they are not representative of all the inventionsdefined by the claims, to be considered limitations on the invention asdefined by the claims, or limitations on equivalents to the claims. Forinstance, some of these advantages may be mutually contradictory, inthat they cannot be simultaneously present in a single embodiment.Similarly, some advantages are applicable to one aspect of theinvention, and inapplicable to others. Furthermore, certain aspects ofthe claimed invention have not been discussed herein. However, noinference should be drawn regarding those discussed herein relative tothose not discussed herein other than for purposes of space and reducingrepetition. Thus, this summary of features and advantages should not beconsidered dispositive in determining equivalence. Additional featuresand advantages of the invention will become apparent in the followingdescription, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of a semiconductor device according to thepresent invention and further details of a process of fabricating such asemiconductor device in accordance with the present invention will bemore clearly understood from the following description taken inconjunction with the accompanying drawings in which like referencenumerals designate similar or corresponding elements, regions andportions and in which:

FIG. 1A-1 and FIG. 1A-2, show an example structure over which exampleembodiments of the present invention are an improvement. FIG. 1A-1 is atop down view of an interconnect structure. FIG. 1A-2 is a crosssectional view along axis 1A-2 in FIG. 1A-1.

FIGS. 1B-1 and 1B-2 show an example embodiment of an interconnect havinga slot according to an example embodiment of the invention. FIG. 1B-2 isa cross sectional view taken along axis 1B-2 in top down view FIG. 1B-1.

FIGS. 1C-1 to 1C-6 show a non-limiting example method for forminginterconnect with slots in wide lines to relieve type 1 stress accordingto an example embodiment.

FIG. 2A-1 shows a top down view of the upper dual damascene interconnectand an underlying wide line over which example embodiments of thepresent invention are an improvement.

FIG. 2A-2 is a cross sectional view of the upper dual damasceneinterconnect and an underlying wide line over which example embodimentsof the present invention are an improvement.

FIG. 2B-1 and 2B-2 show an example embodiment of an interconnect havinga slot that reduces stress such as type 2 stress. FIG. 2B-2 is a crosssectional view taken along axis 2B-2 in top down view FIG. 2B-1.

FIGS. 2C-1 thru 2C-9 show a non-limiting example method of forming aninterconnect structure having a first slot to relieve type 2 stressaccording to an example embodiment.

FIGS. 3A thru 3J shows top down example embodiments of the shapes andpositions of the wide line, slot(s) and via plug according to an exampleembodiments of the invention.

FIGS. 4A thru 4K shows top down example embodiments of the shapes andpositions of the wide line, slot(s) and via plug according to an exampleembodiments of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and more particularly to FIG. 1A-1 andFIG. 1A-2, there is shown an example structure over which exampleembodiments of the present invention are an improvement. It is to beunderstood in this regard that no portion of FIG. 1A-1 or FIG. 1A-2 areadmitted to be prior art. Rather, this highly simplified diagram is aneffort to provide an improved understanding of some problems.

Type 1 Stress—Wide Line 1010 Over the via Plug 1008 that Contacts theLower Line 1004

FIG. 1A-1 shows a top down view of the upper dual damascene interconnect1008 1010, an underlying line 1004 and a dielectric 1006. FIG. 1A-2shows a cross sectional view. The upper dual damascene interconnect iscomprised of a via plug 1008 and a wide line 1010. Type 1 stress 1014 iscreated by the wide line 1010 over the via plug 1008 that contacts thelower line (interconnect) 1004.

Type 1 Stress induced voiding mechanisms can include: 1) vacancies/voidmigration to via bottom and 2) Cu contraction during cooling and hightensile stress up the via.

Type 2 Stress—the via Plug that Contacts the Wide Lower Line

FIG. 2A-1 shows a top down view of the upper dual damascene interconnect1210 1208, an underlying wide line 1202, and dielectric 1206. FIG. 2A-2shows a cross sectional view. The upper dual damascene interconnect iscomprised of a via plug 1208 and a line 1210. Type 2 stress is createdby an overlying via plug 1208 that contacts the lower wide line 1202.Type 2 stress mechanism can be similar to type 1.

I. Example Embodiments

Example embodiments of the present invention will be described in detailwith reference to the accompanying drawings. Example embodiments of thepresent invention provide structures and methods of forming slots (e.g.,openings) in wide metal lines near via plugs where the slots relievestress caused by the wide lines and via plugs. In example embodiments,the only slots in the wide lines are slots position near the via plugthat reduce stress.

II. Structure for type 1

FIGS. 1B-1 and 1B-2 show an example embodiment of an interconnect havinga slot that reduces type 1 stress. FIGS. 3A thru 3J shows top downexample embodiments of the shapes and positions of the wide line,slot(s) and via plug.

FIG. 1B-2 is a cross sectional view taken along axis 1B-2 in top downview FIG. 1B-1.

FIGS. 1B-1 and 1B-2 show a dual damascene interconnect Structure 80 84having a slot 81. The figures show a so called type 1 structure where aline 80, wide enough to cause stresses, is over a via plug 84. A stresscreated is type 1 stress.

A dual damascene shaped interconnect can comprise a via plug 84, a firstslot 81 and a wide line 80. The wide line has at least a first slot 81.The slot is a hole or space in the line. The slot can be filled withdielectric material or another metal. The dielectric material caninclude various CVD/Spin on low −K dielectric materials.

Description of the Location and Size of the Slot to Relieve Stress

The slot 81 in the wide line 80 is spaced 83 from the via plug 84 torelieve stress caused by the wide line 80 over a via plug 84. The wideline preferably has a width 80W large enough to cause the (type 1)stress.

Wide Line

The wide line 80 has a width 80W wide enough to cause the (type 1)stress. For example wide line that causes stress can have a widthbetween 1.0 and 20 μm. The wide line can have height 80H between 2000and 6000 Å. The wide line can have width 80W greater than 1.4 μm and aheight greater than 3000 Å. More preferably the wide line has a widthbetween 1 and 10 μm and preferably greater than 1.4 μm.

In another example, a wide line that causes stress can have a width 80Wbetween 2.6 and 105 times the width/diameter of the via plug, (e.g.,0.19 μm).

In another example, a wide line that causes stress can have a height(wide line) to Width (wide line) ratio between 1:2.5 and 1:33.3.

The stresses will increase as the height to width of the wide lineincreases.

Via Plug

The via plug can preferably have a diameter or width between 0.15 and0.5 μm.

The via plug can have shapes such as a cylindrical shape, or rectangularbox shape. Preferably the via plug has a cylindrical shape.

Other Factors for Stress Induced Voiding

Stress-induced voiding can have other structural and processdependencies. For example, weak point in the dual damascene interconnectcan be caused by poor diffusion barrier coverage. Also, the number ofvacancies present in Cu can influence the Stress. A non-optimized annealcan lead to more vacancies and increase in Cu volume can increasevacancies present. The embodiment's slot may be incorporated into linesthat are normally not thought to be at risk for stress for their widewidths.

Slot & Spacing from PLUG

To relieve stress, such as type 1 and 2 stress, the width 81 S of thefirst slot 81 is between about 135 and 315% of the effective diameter84W, (e.g., 0.19 μm) of the via plug 84 and is more preferably between185 and 265% of the effective diameter 84W of the via plug.

Also the slot 81 is spaced a first distance 83 from the via plug 84 sothat the slot relieves stress on the wide line 80 and the via plug 84.

The first slot 81 is preferably positioned a minimum first distance awayfrom the via plug.

The minimum first distance (83) is between the closest point of the slotto the via plug is between 0.05 μm and 0.25 μm. The minimum firstdistance 83 can be between about 26% and 132% of the effective diameter84W, (e.g., 0.19 μm) and more preferably is between about 26 and 53%.

For example, for a wide line 80 with a width 80W of 1.4 μm or greater,the via plug 84 has a diameter 84W of 0.19 μm, and the minimum firstdistance (83) is preferably 0.05 μm.

Preferably, the most distant point of a slot from the via plug ispreferably a distance 81 F between 0.855 and 1.205 μm and morepreferably between 0.955 and 1.105 μm. Preferably, the most distantpoint of a slot from the via plug is preferably a distance 81 F between447 and 632% of the via plug diameter and more preferably between 500and 579%. Beyond this distance, the relives stress appears to decrease.

In a preferred embodiment, referring for example to FIG. 3G, in anembodiment that has 2 or more rows or radius's (or acrs's) of slots, themaximum distance 310 between farthest slot (e.g. 2^(nd) row) and plug isa distance 310 about between 1.355 μm and 2.055 μm and more preferablybetween 1.555 μm and 1.855 μm.

The total length of the first slot 81 is preferably between about 265and 1380% of the effective diameter 84W of the via plug and is morepreferably between about 530 and 1380% of the effective diameter 84W ofthe via plug. The length 81 L of one leg of a L-shaped structure (e.g.,2 legs) of the first slot is preferably between about 265 and 655% ofthe effective diameter of the via plug and more preferably between 350and 525%. For example, for a L shaped slot, the total length is thetotal of the length of the 1^(st) leg and 2^(nd) leg.

The slot 81 can have a width or diameter 81W between 135 and 315% of thewidth/diameter 84W of the via plug 84 and more preferably between 185and 265%.

Shapes of Slot

The first slot can have shape such as a rectangular shape (top view), aL-shaped bar structure (top view), a curve shape bar shape (top view).For example see FIGS. 3A to 3J and 4A to 4K. The parameters discussedabove can apply to the various shapes and combination of shapes shown inthe figs.

A most preferred slot shape that relieves stress is curved shaped slot.A curved shaped slot can effectively block the vacancies diffusing andreduce the effective volume of Cu without significantly increasing themetal line resistance.

Summary of Configuration of Slots, Lines, via Plugs for Type 1 and 2

Below is a table summarizing some dimensions for type 1 and type 2interconnect structure.

TABLE A Some type 1 and 2 dimensions more more preferred preferredpreferred preferred element dimension low high low high other wide lineWidth (80W 1.0 μm 20 μm 1.0 μm 10 μm = or >1.4 (80 or0) or 240W) μm wideline Height 2000 Å 6000 Å 3000 Å 5000 Å (angstroms) via plug width 0.15μm 0.5 μm e.g., 0.19 micron slot width 135% 315% width 185% 265% width(81 or 241) of via plug of via plug slot Length 265% 655% width 350%525% width (81 or 241) of via plug of via plug Min distance 0.05 μm 0.25μm 0.05 μm 0.1 μm (83, 243) between slot and plug Max distance distance81F 0.855 μm 1.205 μm 0.955 μm 1.105 μm 81F between slot and plug Maxdistance distance 310 1.355 μm 2.055 μm 1.555 μm 1.855 μm 310 between(see FIG. 3G) farthest slot (e.g., 2nd row) and plug

III. Type 2 Structure

FIGS. 2B-1 and 2B-2 show an example embodiment of an interconnect havinga slot that reduces stress such as type 2 stress. A so called “type 2”comprises a wide line (with slot) under a via plug is called structure.FIGS. 3A thru 3J shows top down example embodiments (for type 1 and type2 structures) of the shapes and positions of the wide line, slot(s) andvia plug.

FIG. 2B-2 is a cross sectional view taken along axis 2B-2 in top downview FIG. 2B-1.

FIGS. 2B-1 and 2B-2 show an interconnect structure comprising a lowerlevel interconnect comprised of a wide line 240. The lower levelinterconnect can be a dual damascene interconnect with a via plug (notshown) under the wide line 240. The interconnect can be formed in adielectric layer 245. The dielectric layer 245 can be comprised of oneor more dielectric layers and/or capping layers. The wide line 240 has afirst slot 241. The slot can be filled with dielectric or conductivematerial and is most preferably filled with dielectric material.

The upper interconnect is comprised of a via plug 294. In this examplethe via plug 294 is part of a dual damascene interconnect having a upperline 290. The via plug can be also be a stand alone via plug without anoverlying line.

The via plug 294 contacts the top surface of the wide line 240.

The first slot 241 is spaced a minimum first distance 243 from the viaplug 294 so that the first slot relieves stress on the wide line 240 andthe via plug 294. Preferably the first slot 241 is placed a maximumdistance 241F from the via plug 294.

The placement and sizes of the lines, via plugs and slots are thesimilar as described above and below for the type 1 structure exampleembodiments.

IV. 2 or More Slots—For Type 1 and 2 Structures

Referring to FIGS. 3A thru 3J and 4A thru 4K, are top down views exampleembodiments of interconnects with slots. The via plug can be below (seee.g. FIG. 1B-2 “type one structure”) or above (see e.g., FIG. 2B-2,“type 2 structure”) the wide lines with slots. Theses arrangements canbe applied to type 1 or type 2 structures or stresses. The examplesinclude slots formed in one row or radius's from the plug. Preferablythe slots are formed in only one or two rows/radius's from the plug.Other examples show slots formed in two rows or radius's (distances)from the plug.

The size and placement of slot with respect to via plugs and lines ispreferably the same as described above.

FIGS. 3A and 3B show examples of designs with the via plug located neara corner or side of the wide line.

FIG. 3A shows an example where the slot has a top down view curvedshape. Also preferably the slot and the via plug are about concentric.

FIG. 3B shows an example where the slot has a top down view L shape.

FIGS. 3C thru 3J show examples of a dual damascene interconnectstructure where the wide line has more than one slot. The slot arepreferably symmetrical around the via plug.

FIG. 3C and 3D shows examples of embodiments with 3 slots arranged in 2space rows about parallel with a side of the wide line closest to thevia plug. The slot is preferably about centered in the wide line. FIGS.3C and 3D, show an examples where the slot the dual damasceneinterconnect further includes a second slot in the wide line. Preferablythe distance between the first slot and the second slot is between 110%and 150% of the effective diameter/width of the via plug.

FIG. 3E shows a view of curved slots around 3 sides of a via plug.

FIG. 3F shows a view of 2 L shaped slots around 3 sides of a via plug.

FIG. 3G shows a via plug centered in a wide line. A first set of slotsspaced outwardly from the via plug. A second set of slots is spaced fromthe first set of slots. The slot are symmetric along an x and/or y axisthru the via plug.

In a preferred embodiment, referring for example to FIG. 3G, the maximumdistance 310 between farthest slot (e.g. 2^(nd) row) and plug is adistance 310 about between 1.355 μm and 2.055 μm and more preferablybetween 1.555 μm and 1.855 μm.

FIG. 3H shows a 4 radically spaced curved slots arranged aboutconcentric around the via plug.

FIG. 3I shows 4 L-shaped slots arrange symmetrically around the viaplug.

FIG. 3J shows an embodiment where two adjacent via plugs are positionedcontacting the wide line. Four L-shaped slot are positionedsymmetrically around the 2 via plugs.

In general, if the via plug is placed at a corner of a wide line, lessslots are needed. If the via plug is placed at the center of a widemetal line, more slots are needed to reduce problems.

FIGS. 4A thru 4K shows top down example embodiments of the shapes andpositions of the wide line, slot(s) and via plug according to an exampleembodiments of the invention.

FIG. 4A shows an example where the slots have a top down view curvedshape. There are 3 slots. Two slots arranged about an about 90orientation and one a about a 45 degree orientation to the plug.

FIG. 4B show a L shaped slot and two line slots arranged at about 90degree angles.

FIG. 4C shows a straight slot with the plug located in the middle andnear one end of the line.

FIG. 4D, shows two curved slots around a plug located in the middle andnear one end of the line.

FIG. 4E shows three curved slots positioned at 2 (distances) radiuses orrows around the plug.

FIG. 4F shows five slots positioned in 2 rows or radius's around theplug.

FIG. 4G shows two L-shaped slots and a straight slot around a plug.

FIG. 4H shows two curved slots around a plug.

FIG. 4I shows two sets of two curved slots around a plug.

FIG. 4J shows two sets of four curved slots (in 2 radius's) around aplug.

FIG. 4k shows two L-shaped slots and four straight slot around plug.

In the embodiments shown in FIG. 3A to 3J and 4A to 4K, the exampleparameter (e.g., dimensions) described above can be used. For example,total length of a slot is preferably between about 265 and 1380% of theeffective diameter of the via plug (e.g., 0.19 microns) and morepreferably between 530 and 1380%. For example, the length single lineslot or curved slot can be between about 265 and 655% of the effectivediameter (e.g., 0.19 microns)of the via plug and more preferably between350 and 525%.

V. Example Method Embodiment for Slots in Lines A. Type 1

FIGS. 1C-1 to 1C-6 show a non-limiting example method for forming anembodiment with slots in wide lines to relieve type 1 stress. There aremany methods and variations for forming the embodiments.

Below, the terms “first, second, etc.” levels are relative terms and donot refer to absolute positions.

Referring to FIG. 1C-1, we form a first barrier layer 22 over asemiconductor structure 12. The first barrier layer (an other barrierlayers) can be comprised of silicon nitride.

Semiconductor structure 12 is understood to possibly include asemiconductor wafer, active and passive devices formed within the wafer;and insulating and conductive layers formed on the wafer surface. Theterm “structure surface” is meant to include the upper most exposedlayers over a semiconductor wafer, such as a silicon surface, aninsulating layer and/or conductive lines.

Preferably the top surface of the semiconductor structure 12 iscomprised for the top surface of an dielectric layer, such as ainterlevel dielectric or inter metal dielectric layer and furthercomprise exposed interconnects or contacts to underlying devices.

Next, we form a first ILD layer 24 over the first barrier layer 22.

Still referring to FIG. 1C-1, we form a lower line (interconnect) 30over the semiconductor structure 12 in a lower line opening in the firstbarrier layer 22 and the first ILD layer 24.

We then form an upper first level barrier layer 32 over the lower line(interconnect) 30 and first ILD layer 24.

We form sequentially a lower (e.g. second level) dielectric layer 34, amiddle (second level) barrier layer 36 and a upper (second level)dielectric layer 38 and a upper (second level) barrier layer 40 over theupper first level barrier layer 32. The middle barrier layer can beoptional. The dielectric layers can be comprised of Low-K material.

We form a via plug mask layer 54 having a via plug mask opening over theupper (second level) dielectric layer 38.

Referring to FIG. 1C-2, we form a via plug hole 50 in the a lower(second level) dielectric layer 34, a middle (second level) barrierlayer 36 and an upper (second level) dielectric layer 38 and an upper(second level) barrier layer 340 to preferably expose the barrier layer32.

We then remove the via plug mask layer 54.

We form an organic plug 56 at least partially filling the via plug hole50. The organic plug is preferably comprised of a BARC.

Referring to FIG. 1C-2, we form a mask layer 62 having a slot maskpattern 62A that defines a first slot in a wide line. The mask layer 62has openings 60 that defines the wide line.

Referring to FIG. 1C-3, we form a wide line opening 68 in the upperdielectric layer 38 and a first slot dielectric portion 38A by using themask layer 62 as an etch mask.

As shown in FIG. 1C-4, we remove the mask layer 62 and the remainingorganic plug (e.g., BARC) 56.

As shown in FIG. 1C-5, we remove the barrier layer 32 in the via opening50 preferably using a breakthrough etch.

Referring to FIG. 1C-6, we form an interconnect 80 84 in the via opening50 and the wide line opening 68.

The interconnect 80 84 contacts the lower line 30. The interconnect 8084 comprised of a via plug 84 and a wide line 80. The interconnect ispreferably formed by a Cu plating process and CMP back to planarize.

The slot 81 and first slot dielectric portion 38A are positioned in thewide line 88 so that the first slot dielectric portion 38A relievesstress on the via plug 84 and the lower line 30. The slots arepositioned and sized as described above to reduce stress inducedvoiding. The slots reduce the effective Cu volume to reduce the numberof vacancies available for diffusing during stress and Cu volumecontracting during cooling. The slots also block diffusion of vacanciesduring stress.

The first slot dielectric portion 38A defines a first slot 81 in thewide line 88.

B. Example Embodiment of a Type 2 Method

FIGS. 2C-1 thru 2C-6 show a non-limiting example method of forming aninterconnect structure having a first slot to relieve type 2 stress.

The terms “first, second, etc.” levels are relative terms and do notrefer to absolute positions.

Referring to FIG. 2C-1, we form a lower (first level) barrier layer 220,a dielectric (e.g., inter metal dielectric) layer 224 and a first levelupper barrier layer 226 over a semiconductor structure 210.

A slotted wide line resist pattern 230 230A is formed over the firstlevel upper barrier layer 226.

Referring to FIG. 2C-2, using the slotted wide line resist pattern 230230A, we etch a slotted wide line opening 234 in the inter metaldielectric layer 224 and the upper barrier layer 226. The slotted wideline opening 234 defined at least by a dielectric first slot portion224A.

Referring to FIG. 2C-2, the slotted wide line resist pattern 230 230A isthen removed.

Referring to FIG. 2C-3, we then etch the lower (first level) barrierlayer 220 in the wide line opening 234 to expose the semiconductorstructure 210.

Referring to FIG. 2C-4, we form a wide line 240 filling the wide lineopening 234. The dielectric first slot portion 224A forms a first slot241 (opening) in the wide line 240.

Referring to FIG. 2C-5, we form a lower dielectric layer 254, a middlebarrier layer 258 and an upper dielectric layer 262 and an upper barrierlayer 264 over the wide line 240 and dielectric layer 224.

Referring to FIG. 2C-5, we form a via hole mask 266 having a via holemask opening 268 over the upper dielectric layer 262 and the barrierlayer 264.

Referring to FIG. 2C-6, then we form a via hole 270 in the lowerdielectric layer 254, a middle barrier layer 258 and an upper dielectriclayer 262 and an upper barrier layer 264.

We remove the via hole mask 266.

Referring to FIG. 2C-6, we form a line mask 274 having a line maskopening 278 over the upper barrier layer 264.

Referring to FIG. 2C-7, we form an organic plug 275 at least partiallyfilling the via hole 270.

Referring to FIG. 2C-7, we form a line opening 280 in the a middlebarrier layer 258, an upper dielectric layer 262 and an upper barrierlayer 264.

Referring to FIG. 2C-8, we remove the line mask 274 and the BARC plug276. The barrier layers are removed in the openings and over thedielectric 268.

Referring to FIG. 2C-9, we form an interconnect 290 294 in the lineopening 280 and the via opening 270.

The interconnect 290 294 is preferably comprised of a via plug 294 and aline 290. The interconnect is preferably formed by a Cu plating andchemical-mechanical polish (CMP) planarization process.

A top cap layer 298 is formed.

The via plug contacts the wide line 240 and preferably does not contactthe dielectric first slot portion 224A.

The dielectric first slot portion 224A is positioned with respect to thevia plug so that the first slot dielectric portion 224A relieves stresson the via plug 294 and the wide line 240. The first slot dielectricportion 224A is positioned as described above.

The first slot dielectric portion 224A defines a first slot in the wideline 240.

The embodiments slots in wide lines serve a different purpose that slotformed in line to reduce dishing from chemical-mechanical polish (CMP)processes and slot formed to modify the line resistance. Theembodiment's slots are sized and positioned to reduce stress. Inembodiments, the only slots in the wide lines are slots position nearthe via plug that reduce stress.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between (andincluding) the recited minimum value of 1 and the recited maximum valueof 10, that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10.

In the above description numerous specific details are set forth such aswidths, thicknesses, etc., in order to provide a more thoroughunderstanding of the example embodiments of the present invention. Itwill be obvious, however, to one skilled in the art that the presentinvention may be practiced without these details. In other instances,well known process have not been described in detail in order to notunnecessarily obscure the present invention.

While the invention has been particularly shown and described withreference to the preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade without departing from the spirit and scope of the invention. It isintended to cover various modifications and similar arrangements andprocedures, and the scope of the appended claims therefore should beaccorded the broadest interpretation so as to encompass all suchmodifications and similar arrangements and procedures.

What is claimed is:
 1. A device comprising: a substrate; a dielectriclayer disposed over the substrate, wherein the dielectric layercorresponds to an interconnect level of the device; and a continuousconductive line disposed in a trench in the dielectric layer, whereinthe continuous conductive line surrounds at least one dielectricstructure within the continuous conductive line, the dielectricstructure partially interrupts the continuous conductive line, whereinthe dielectric structure is positioned in a portion of the continuousconductive line which has a via plug in communication therewith.
 2. Thedevice of claim 1 wherein the dielectric structure is of a sufficientdimension to reduce stress related defects in the continuous conductiveline and the via plug in a via level which is in communication with thecontinuous conductive line in proximity of the dielectric structure. 3.The device of claim 1 wherein: the dielectric structure is of sufficientsize to reduce stress related defects in the continuous conductive lineand the via plug in a via level in communication with the continuousconductive line in proximity of the dielectric structure; and thecontinuous conductive line comprises copper.
 4. The device of claim 1wherein the continuous conductive line comprises a plurality ofdielectric structures therein, the dielectric structures are ofsufficient size to reduce stress related defects in the continuousconductive line and the via plug in communication with the continuousconductive line in proximity of the dielectric structures.
 5. The deviceof claim 4 wherein: the via plug is located at a bottom surface or a topsurface of the continuous conductive line; and the continuous conductiveline containing the dielectric structures comprises a wide conductiveline and the via plug is in communication with a narrow conductive line.6. The device of claim 4 wherein the dielectric structures are disposedcompletely within the trench such that the dielectric structures formdielectric islands within the continuous conductive line.
 7. The deviceof claim 1 wherein: the continuous conductive line comprises a pluralityof dielectric structures therein, the dielectric structures are ofsufficient size to reduce stress related defects in the continuousconductive line and the via plug in communication with the continuousconductive line in proximity of the dielectric structures; and thecontinuous conductive line comprises copper.
 8. The device of claim 7wherein: the via plug is located on a bottom surface or a top surface ofthe continuous conductive line; and the continuous conductive linecontaining the dielectric structures comprises a wide conductive lineand the via plug is in communication with a narrow conductive line.
 9. Adevice comprising: a substrate; a dielectric layer disposed on thesubstrate; and a continuous conductive line disposed in a trench in thedielectric layer corresponding to the continuous conductive line,wherein the continuous conductive line surrounds at least one dielectricstructure disposed in a portion of the trench, wherein the dielectricstructure creates a partial discontinuity within the continuousconductive line, the dielectric structure is disposed within a distancefrom a via plug in a via level which is in communication with thecontinuous conductive line.
 10. The device of claim 9 wherein a minimumdistance away from the via plug is between about 0.05 μm and 0.12 μm anda maximum distance between the dielectric structure and the via plug isbetween about 0.855 μm and 1.205 μm.
 11. The device of claim 9 whereinthe dielectric structure is of a sufficient size to reduce stressrelated defects in the continuous conductive line and the via plug. 12.The device of claim 11 wherein the dielectric structure comprises: awidth between about 135 and 315% of an effective diameter of the viaplug; and a total length between about 265 and 1380% of the effectivediameter of the via plug.
 13. The device of 9 wherein the continuousconductive line comprises a plurality of dielectric structures disposedin the trench and discontinuously surround the via plug.
 14. The deviceof claim 13 wherein the dielectric structures form a plurality ofgeometrically discontinuous concentric rows of structures in thecontinuous conductive line around the via plug.
 15. The device of claim14 wherein: a minimum distance between the dielectric structures and thevia plug is about 26 and 63% of an effective diameter/width of the viaplug; and a maximum distance bwteeen the dielectric structures and thevia plug is between 0.855 μm and 2.055 μm.
 16. A device comprising: asubstrate; a dielectric layer disposed on the substrate, wherein thedielectric layer comprises a trench corresponding to a continuousconductive line, wherein the trench includes at least one dielectricstructure; a continuous conductive line disposed in the trench of thedielectric layer, wherein the continuous conductive line surrounds theat least one dielectric structure, wherein the dielectric structurecreates a partial discontinuity within the continuous conductive line,the dielectric structure is disposed in a portion of the trench that isproximal to the continuous conductive line which has a via plug incommunication therewith.
 17. The device of claim 16 wherein: the viaplug is located on a bottom surface or a top surface of the continuousconductive line; and the continuous conductive line containing thedielectric structure comprises a wide conductive line and the via plugis in communication with a narrow conductive line.
 18. The device ofclaim 17 wherein the dielectric structure is of a sufficient dimensionto reduce stress related defects in the continuous conductive line andthe via plug in a via level which is in communication with thecontinuous conductive line in proximity of the dielectric structure. 19.The device of claim 17 wherein the continuous conductive line comprisesa plurality of dielectric structures therein, the dielectric structuresare of sufficient size to reduce stress related defects in thecontinuous conductive line and the via plug in communication with thecontinuous conductive line in proximity of the dielectric structures.20. The device of claim 19 wherein the dielectric structures comprise ageometric shape including rectangular shape, L-shape, curve shape or acombination thereof.